Universiti Putra Malaysia Development Of Scara Robotic Arm And Control .

UNIVERSITI PUTRA MALAYSIADEVELOPMENT OF SCARA ROBOTIC ARM ANDCONTROL SYSTEM FOR LABORATORYAUTOMATIONJOHNNY KOH SIAW PAWFK 2002 51

DEVELOPMENT OF SCARA ROBOTIC ARM AND CONTROL SYSTEMFOR LABORATORY AUTOMATIONByJOHNNYKOBSIAWPAWThesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia,in Fulfilment of the Requirement for the Degree of Master of ScienceJuly 2002

Abstract of thesis presented to the Senate ofUniversiti Putra Malaysia in fulfilmentof the requirements for the degree of Master of ScienceDEVELOPMENT OF SCARA ROBOTIC ARM AND CONTROL SYSTEMFOR LABORATORY AUTOMATIONByJOHNNYKOHSIAWPAWJuly 2002Chairman:Dr. Ishak Bin ArisFaculty:EngineeringRecent developments in robotic system usage for material handlings, examine thevarious benefits of its applications in the chemical industIy environment. In orderto avoid the risk factor in chemical handling, various steps can be taken. One of theprominent methods is by substituting the human hands with the robotic ann inhandling dangerous and erosive chemicals. It is with these reasons that this studywas conducted with the primary objective to develop a system that wouldcontribute towards encouraging a safety way of chemical testing and processing.This thesis provides an early analysis of robotic developments in the areaII

The objective of this project is to develop a SCARA robotic ann and the intelligentcontrol system. The design and development of this project involves three majorsections. First section concerns about software programming, while the secondsection involves hardware construction and the final section deals with the graphicuser interfacing (GUI).The hardware design can mainly be categorised into electrical design andmechanical design. Electrical design involves proper electrical wiring of input andoutput devices power distributions, safety devices, interfacing devices and controlcomponents. The mechanical design is referred to the construction of the robot armstructures. These comprise mechanical drawings, mechanical simulations,mathematical calculations, as well as parts fabrication. On the otherhan thedesign of software will consist of input and output assignments, program flowcharts, robot-learning method and MINT programming. Design of GUI willinvolve Visual Basic (Professional Edition) programming.Basically, this project comprises several subsystems, namely: a sensor system,which is used to obtain data about the state of the mechanism and the environment,a controller and drivers, to guide the mechanism and the sensors in a desiredmanner, a planning and control system that decides on the actions and also consistsof a power distributions system. The specified function of the robotic system isaccomplished by intelligent interpretation of sensor infonnation and mechanicalactuations in tenn of plan, task and model.111

The entire robotic system was carefully and meticulously designed, constructedand tested. From the experimental results, it is proven that the proposed roboticsystem was successfully developed. This robotic ann can handle hazardous tasks inlab experiment specifically regarding chemical processing. Thus, reducing the riskon human.IV

Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysiasebagai memenuhi kepeduan untuk ijazah Master SainsPEMBANGUNAN LENGAN ROBOT SCARA DAN SISTEM KAW ALANUNTUKAUTOMAm OlehJOHNNY KOH SlAW PAWJulai 2002Pengerusi:Dr. Ishak Bin ArisFalmlti:KejuruteraanBam-bam pembangunan dalam penggunaan sistem robotik untuk mengwuskanbahan membuktikan pelbagai kebaikannya dalam industri bahan kimia. Demi\Ultuk mengelak dari risiko pengendalian bahan kimia, pelbagai langkah bolehdiambil. Salah sam langkah penting ialah dengan menggantikan tangan manusiadengan tangan robot untuk mengendalikan bahan-bahan kimia berbahaya danmenghakis. Untuk tujuan inilah, kajian ini dijalankan dengan matlamat utamauntuk menghasilkan sebuah sistem yang dapat menyumbang kepada keselamatanpemprosesan dan pengujian bahan kimia. Tesis ini menyediakan analisis awaldalam pembangunan robot dalam bidang berkenaan.v

Objektif projek adalah untuk menghasilkan sebuah robot jenis SCARA dengansistem kawalannya. Rekabentuk dan pembangunan projek akan melibatkan tigabahagian penting. Bahagian pertama menitikberatkan bidang perisian manakalabahagian kedua meliputi pembinaan perkakasan, dan disusuIi dengan antaramukapengguna secara grafik.Rekabentuk perkakasan bolehlah dikategorikan kepada rekabentuk elektrikal danrekabentuk mekanikal. Rekabentuk elektrikal merangkumi pendawaian alatanmasukan dan keluaran, pengagihan kuasa, peranti keselamatan dan komponenkawalan. Rekabentuk mekanikal meliputi pembinaan struktur robot Ini termasuklukisan dan simulasi mekanikal, turut melibatkan pengiraan dan fabrikasibahagian-babagian robot Rekabentuk perisian pula akan meh1 atkan penugasanmasukan dan keluaran, carta-carta aliran program, teknik robot-belajar anmeliputipengaturcaraan Visual Basic.Secara asasnya, projek ini membabitkan beberapa sub-sistem iaitu sistem penderiayang digunakan untuk mendapatkan maklumat keadaan mekanisme danpersekitaran, pengawal dan pemacu untuk mengawal mekanisme dan penderia,sistem kawalan dan juga sistem pengagihan kuasa. Fungsi khas sistem robotikdicapai dengan penterjemahan maklumat-maklumat penderia dan pemacuanmekanikal.VI

Keseluruhan sistem robotik ini telah direkabentuk, dibina dan diuji secara teliti.Daripada keputusan ujikaji, temyata sistem robot yang dicadangkan telah berjayadihasilkan. Tangan robot ini berupaya untuk mengendalikan kerja-kerja berbahayadalam ujikaji makmal terutamanya pemprosesan bahan kimia. Pada masa yangsarna, ini turut mengurangkan risiko kepada manusia.vii

ACKNOWLEDGEMENTSThe success of this project involves many valued contributions from anumber of persons. I am grateful to my project supervisor, Dr. Ishak Aris for hisinvaluable supervision, advice and guidance in the development of this project tillits completion. He has given me lot of encouragements, and supports that hadmotivated me to successfully managed this project.A word of thanks to the project co-supervisors, Dr. Sinan Mahmod andProf. Madya Jr. Dr. Norman Mariun, who gave us the opportunity and support tohandle this project. I would also like to thank the staffs of Faculty of Engineering,especially to En. Tajul Ariffin and En. Muzamir for their contribution in providingthe related supporting materials.I am deeply indebted to Mr. S. Y. Koh and Mr. S.K. Koh, the managers ofAutocomsign Enterprise, who have shared their expertise and comments. Mr. Y.S.Chee, Mr. J.H. Ong and Mr. Y.K. Tai, whose professional careers have alwaysrevolved around motion control, reviewed the motion systems chapter for me, andparticipated in many more technical discussions. Finally, thanks to my colleagueJenny Teh, who has given me great support on this project.It is my hope that this report will contribute to the organisations infurthering their research.viii

I certify that an Examination Committee met on 11th July 2002 to conduct the finalexamination of Johnny Koh Siaw Paw on his Master of Science thesis entitled"Development of Scara Robotic Ann and Control System for Laboratory Automation"in accordance with Universiti Pertanian Malaysia (Higher Degree) Act 1980 andUniversiti Pertanian Malaysia (Higher Degree) Regulations 1981. The Committeerecommends that the candidate be awarded the relevant degree. Members of theExamination Committee are as follows:NASRULLAH KHAN, Ph.D.Faculty of Engineering,Universiti Putra Malaysia(Chairman)ISHAK BIN ARIS, Ph.D.Faculty of Engineering,Universiti Putra Malaysia(Member)SINAN MAHMOD, Ph.D.Facuhy of Engineering,Universiti Putra Malaysia(Member)NORMAN MARIUN, Ph.D.Associate ProfessorFaculty of Engineering,Universiti Putra Malaysia(Member) -:JSHAMSHER MOHAMAD RAMADILI, Ph.D.ProfessorlDeputy DeanSchool of Graduate StudiesUniversiti Putra MalaysiaDate: 1 jSEP 2002IX

This thesis submitted to the Senate of Universiti Putra Malaysia has been accepted asfulfillment of the requirement for the degree of Master of Science. The members of theSupervisory Committee are as follows:ISHAK BIN ARIS, Ph.D.Faculty of Engineering,Universiti Putra Malaysia(Member)SINAN MAHMOD, Ph.D.Faculty of Engineering,Universiti Putra Malaysia(Member)NORMAN MARIUN, Ph.D.Associate ProfessorFaculty of Engineering,Universiti Putra Malaysia(Member)AINI IDERIS, Ph.D.Professor/ Dean,School of Graduate Studies,Universiti Putra MalaysiaDate:x

I hereby declare that the thesis is based on my original work except for quotations andcitations, which have been duly acknowledged. I also declare that it has not beenpreviously or concurrently submitted for any other degree at UPM or otherinstitutions.JOHNNYKOHSIAWPAWXl

TABLE OF L SHEETSDECLARATION FORMLIST OF TABLESLIST OF FIGURESLIST OF ABBREVIATIONSLIST OF N1.1Introduction1.2Objectives of the Project1.3Overview of the Project1.4Layout of the ThesisLITERATURE REVIEW2.1Modem Technology of Robots2.2Applications of Robot2.3Laws of RobotsClassification of Robots2.42.5Robot Configurations2.6Drive Technology2.7Types of Robotic Controller and Programming Software2.7.1 Smart Step Controller2.7.2 Motion Interpreter (MINT) Language2.7.3 Terminal Emulator (cTERM)2.7.4 Programming Technique Using MINT andTerminal Emulator for Developing the ControlSoftware2.7.5 Graphic User Interfacing (GUI)2.7.6 Technique of Using Visual Basic for DevelopmentofGUI2.8Intelligent Robotic Systems2.9The Main Types of Robot-Learning2.9.1 Learning Functions2.9.2 Learning About the World2.9.3 Learning to Coordinate 132.142.142.162.172.] 82.202.212.222.22XlI

Learning New BehavioursSummary of Literature Software Design and Development3.2.1 System Control Software3.2.1.1 MainProgram3.2.1.2 Process Routine3.2.1.3 Learning Routine3.2.1.4 Inputs and Outputs Assignment3.2.2 Development of the GUI for the Proposed Robot3.2.2.1 Graphical Design3.2.2.2 Parallel Port Control3.3Hardware Development3.3.1 Electrical Design3.3.1.1 Electrical Protection System3.3.1.2 Power Distribution System3.3.1.3 Input and Output Module3.3.1.4 Electro-Pneumatic Based Gripper System3.3.1.5 Stepper Motor Control3.3.1.6 110 Isolation Card for GUI3.3.1.7 Controller Wiring3.3.2 Mechanical Design3.3.2.1 Elevation Module3.3.2.2 Upper Arm and Fore Arm Modules3.3.2.3 Gripper Module3.3.2.4 Leadscrew, Belt and Bearing Systems3.3.2.5 Jigs, Fixtures and Mechanical Base3.4System 33.543.55RESULTS AND DISCUSSIONOverviewHardware Testing4.2.1 Electrical Module4.2.1.1 Electrical Protection System4.2.1.2 Power Distribution System4.2.1.3 Input and Output Module4.2.1.4 Electro-Pneumatic Based Gripper System4.2.1.5 Stepper Motor Control4.2.1.6 GUl 110 Isolation Card4.2.2 Mechanical Modules4.2.2.1 Elevation Module4.2.2.2 Upper Arm and Fore Arm Modules4.2.2.3 Gripper System4.2.2.4 Kinematics 304.314.14.2XlII

4.3Software Testing4.3.1 Process Routine4.3.2 Learning Routine4.3.3 Graphical User InterfacingSystem DICESAppendix A: Mechanical DrawingsAppendix B: ProgramAppendix C: Electrical DesignAppendix D: Mechanical ComponentsAppendix E: Electrical ComponentsAppendix F: Pneumatic SystemVITAA.IB.1C.1D.1E.1F.lV.IXIV

LIST OF TABLESPageTable3.1Inputs Assignment3.143.2Outputs Assignment3.153.3Output Pins for Parallel Port Control3.l93.4Input Pins for Parallel Port Control3.193.5Analogue Inputs3.303.6Load Calculation Results3.514.1Current Path Characteristic4.54.2Temperature Measurement of Motor Case by Using Thermometer 4.284.3Kinematics Parameters4.344.4Robot Specifications4.454.5Robot Arm Performance4.46xv